Honeycomb crash pad

Abstract

A crash pad for use in vehicle interiors. The crash pad includes an energy-absorbing honeycomb which has a cover plate attached thereon to prevent noise from being generated due to contact between the crash pad and vehicle interior surface during normal vehicle operation. The cover plate is attached on one side to the honeycomb with the other side being molded to match the shape of the interior surface of the vehicle. The cover plate includes positioning devices which locate and hold the crash pad during interior panel fabrication. The cover plate protects the honeycomb and the technician during handling and installation. The cover plate also helps to retain the shape of the honeycomb and provides a suitable surface for labels that may contain product identification and other information needed during use of the pads in mass production of vehicles.

What is claimed is: 
     
       1. A honeycomb crash pad adapted for use in the interior of a vehicle wherein said crash pad is located adjacent to an interior surface of said vehicle, said honeycomb crash pad comprising: a honeycomb made from energy absorbing material, said honeycomb comprising: a first face which is located nearest to the interior surface of said vehicle when said honeycomb crash pad is located adjacent to said interior surface, said first face having a perimeter;   a second face which is located furthest from said interior surface when said honeycomb crash pad is located adjacent to said surface, said second face having a perimeter; and   a side surface which extends between said first and second faces at the perimeter of said first and second faces;   a cover plate having an outside surface, an inside surface and a perimeter wherein said outside surface is shaped to match said interior surface of said vehicle and said inside surface is shaped to match the first face of said honeycomb, said inside surface being attached to said honeycomb first face; and   one or more positioning indentations located on the outside surface of said cover plate.     
     
     
       2. A honeycomb crash pad according to claim 1 wherein said energy absorbing material is aluminum. 
     
     
       3. A honeycomb crash pad according to claim 1 wherein said cover plate comprises a lip around the perimeter of said cover plate, said lip extending over the side surface of said honeycomb. 
     
     
       4. A honeycomb crash pad according to claim 1 wherein said cover plate consists essentially of a plastic material. 
     
     
       5. A panel for use in the interior of a vehicle wherein said panel is located adjacent to an interior surface of said vehicle, said panel comprising: a liner comprising an inward surface which is located furthest away from the interior surface of said vehicle, an outward surface which is located closest to the interior surface of said vehicle and a perimeter;   at least one honeycomb crash pad mounted on the outward surface of said liner, said honeycomb crash pad comprising: a honeycomb made from energy absorbing material, said honeycomb comprising: a first face which is located nearest to said interior surface of the vehicle when said honeycomb crash pad is located adjacent to said interior surface, said first face having a perimeter;   a second face which is located furthest from said interior surface when said honeycomb crash pad is located adjacent to said interior surface, said second face having a perimeter; and   a side surface which extends between said first and second faces at the perimeter of said first and second faces;   a cover plate having an outside surface, an inside surface and a perimeter wherein said outside surface is shaped to match said interior surface of said vehicle and said inside surface is shaped to match the first face of said honeycomb, said inside surface being attached to said honeycomb first face; and   one or more positioning indentations located on the outside surface of said cover plate.       
     
     
       6. A panel according to claim 5 wherein said energy absorbing material is aluminum. 
     
     
       7. A panel according to claim 5 wherein said cover plate comprises a lip around the perimeter of said cover plate, said lip extending over the side surface of said honeycomb. 
     
     
       8. A panel according to claim 5 wherein said cover plate consists essentially of a plastic material. 
     
     
       9. A panel according to claim 5 wherein said panel is a headliner. 
     
     
       10. A vehicle comprising: an interior surface comprising one or more positioning points; and   a panel which is located adjacent to said interior surface, said panel comprising: a liner comprising an inward surface which is located furthest away from the interior surface of said vehicle, an outward surface which is located closest to the interior surface of said vehicle and a perimeter;   at least one honeycomb crash pad mounted on the outward surface of said liner, said honeycomb crash pad comprising: a honeycomb made from energy absorbing material, said honeycomb comprising: a first face which is located nearest to said interior surface of the vehicle when said honeycomb crash pad is located adjacent to said interior surface, said first face having a perimeter;   a second face which is located furthest from said interior surface when said honeycomb crash pad is located adjacent to said interior surface, said second face having a perimeter;   a side surface which extends between said first and second faces at the perimeter of said first and second faces; and   a cover plate having an outside surface, an inside surface and a perimeter wherein said outside surface is shaped to match said interior surface of said vehicle and said inside surface is shaped to match the first face of said honeycomb, said inside surface being attached to said honeycomb first face; and   one or more positioning indentations located on the outside surface of said cover plate wherein said positioning indentations engage said positioning points to provide positioning of said panel relative to said interior surface.         
     
     
       11. A vehicle according to claim 10 wherein said energy absorbing material is aluminum. 
     
     
       12. A vehicle according to claim 10 wherein said cover plate comprises a lip around the perimeter of said cover plate, said lip extending over the side surface of said honeycomb. 
     
     
       13. A vehicle according to claim 10 wherein said cover plate consists essentially of a plastic material. 
     
     
       14. A vehicle according to claim 10 wherein said panel is a headliner. 
     
     
       15. A honeycomb crash pad according to claim 1 which further comprises protuberances located on the outside surface of said cover plate, said protuberances comprising an end surface for contacting the interior surface of said vehicle. 
     
     
       16. A panel according to claim 5 which further comprises protuberances located on the outside surface of said cover plate, said protuberances comprising an end surface for contacting the interior surface of said vehicle. 
     
     
       17. A vehicle according to claim 10 which further comprises protuberances located on the outside surface of said cover plate, said protuberances comprising an end surface for contacting the interior surface of said vehicle.